Production audit
It is not always possible to establish a dialogue between design and technology teams on the source of high vibrations. Therefore, we can act as an independent auditor and review the production technology.
The audit goal is to check compliance of the parts specified balancing technical requirements with the actual ones.
Works performed:
- Analysis of balancing technology documentation;
- Study of tooling manufacturing documentation;
- Inspection of the facilities certification;
- Inspection of compliance of the operations performed with the balancing specifications;
- Experimental and analytical determination of production errors in the “balancing facility-tooling-rotor” systems and “facility-faceplate-clamps-workpiece”.
Result:
- Recommended improvement of the rotor balancing accuracy.
Audit of design documentation
Specific features of aircraft rotors do not allow direct application of balancing standards. These standards are advisory in nature. Therefore, balancing tolerances for each rotor and its parts are assigned by designers individually, depending on the experience and production capabilities. The validity of these values always seems ambiguous.
The goal of the design documentation audit is to identify the compliance of theoretically substantiated technical requirements with those actually specified in the drawings.
Works performed:
- Calculation of the rotor initial, residual, manufacturing and assembling unbalances;
- Analysis of the balancing and assembling stages, as well as the related production errors;
- Simulation in DYNAMICS R4 of the technology errors influence;
- Calculation of acceptable imbalances and deflections;
- Statistical analysis of imbalances parts, assemblies and rotors, determination of constant and systematic errors in their manufacturing.
- Identification of the correlation between measured vibrations and assembling and balancing errors.
- Identification of dominant errors.
- DYNAMICS R4 computer simulation of general engine vibrations caused by the actual imbalances, identification an unfavorable combination of rotor imbalances.
Result:
- Recommendations for the balancing technology improvement.